Method for molding an object containing a radio frequency identification tag

Abstract

A method for applying a radio frequency identification tag to an object, e.g., a container, by means of an insert molding process or in-mold decorating process. Such a method can be utilized to simplify the manufacturing processes for applying a radio frequency identification tag to an object, e.g., a container. The molding process can be a conventional molding process, such as, for example, injection molding, blow molding, compression molding, transfer molding, and rotational molding. However, the conventional molding process is modified by inserting a radio frequency identification tag into the cavity of the mold prior to forming the molded article. The modified molding process results in a molded article having a radio frequency identification tag encapsulated by the polymeric material of the molded article.

1. A method for attaching a RFID tag to a container for use in an automated diagnostic analyzer, the process comprises the steps of:
 (a) providing a roll of adhesive coated composite film, the adhesive coated composite film comprising a polymeric backing, a layer of release liner, and a layer of radiation-curable adhesive between the polymeric backing and the layer of release liner, one major surface of the layer of radiation-curable adhesive being in face-to-face contact with one major surface of the polymeric backing and the other major surface of the layer of radiation-curable adhesive being in face-to-face contact with one major surface of the release liner; 
 (b) forming a part from the adhesive coated composite film for bearing a radio frequency identification tag, the part formed by means or thermoforming; 
 (c) removing the layer of release liner from the thermoformed part; 
 (d) providing a roll comprising a plurality of radio frequency identification tags, the radio frequency identification tags in face-to-face contact with a layer of protective film; 
 (e) at least partially embedding the radio frequency identification tags in the radiation-curable adhesive of the thermoformed part; 
 (f) fixing the radio frequency identification tag by means of a radiation curing process to form an assembly comprising a layer of polymeric backing, radio frequency identification tags, and a layer of protective film; 
 (g) cutting the assembly in step (f) by means of a cutting apparatus to form an assembly comprising a polymeric backing, a single radio frequency identification tag, and a layer of protective film; 
 (h) molding an article in a mold and attaching the radio frequency identification tag to the molded container in the mold; and 
 (i) releasing the molded article to which the radio frequency identification tag is attached from the mold. 
 
     
     
       2. The method of  claim 1 , wherein the article is a container. 
     
     
       3. The method of  claim 2 , wherein the container is a micro-well plate. 
     
     
       4. The method of  claim 1 , wherein the molding step utilizes insert molding. 
     
     
       5. The method of  claim 1 , wherein the molding step utilizes injection molding. 
     
     
       6. The method of  claim 1 , wherein the adhesive coated composite film is heated prior to undergoing step (b). 
     
     
       7. The method of  claim 1 , wherein the radio frequency identification tags are provided in the form of a roll. 
     
     
       8. The method of  claim 1 , wherein the radiation-curable adhesive is curable by ultraviolet radiation. 
     
     
       9. The method of  claim 1  wherein the adhesive coated composite film is prepared by a method comprising the steps of:
 (a) providing a polymeric backing; 
 (b) coating a layer of radiation-curable adhesive onto one major surface of the polymeric backing to form a two layer composite film; and 
 (c) applying a layer of release liner over one major surface of the layer of radiation-curable adhesive. 
 
     
     
       10. The method of  claim 9 , wherein the layer of radiation-curable adhesive is coated onto one major surface of the polymeric backing to form a two layer composite film by means of transfer roll coating. 
     
     
       11. The method of  claim 1 , wherein the assembly comprising a layer of polymeric backing, a radio frequency identification tag, and a layer of protective film is transferred from the cutting station to the mold by means of a conveyor belt. 
     
     
       12. The method of  claim 1 , wherein the assembly comprising a layer of polymeric backing, a radio frequency identification tag, and a layer of protective film is transferred from the cutting station to the mold by means of a robotic mechanism.